Exposing the pitfalls of plastics mechanical recycling through cost calculation

Area of Science:

• Environmental Economics
• Materials Science
• Industrial Ecology

Background:

• The European Union (EU) has set ambitious recycling targets for the plastic industry.
• The economic viability of mechanical plastic recycling is a critical factor in achieving these targets, alongside technological challenges.
• Accurate cost calculation is essential for effective plastic recycling strategies.

Purpose of the Study:

• To expose significant pitfalls in the mechanical plastic recycling process through business economic cost calculation.
• To analyze the influence of various factors like scale, mass retention, processing capacity, and waste composition on recycling costs.
• To provide a holistic insight into the cost implications across the entire recycling chain.

Main Methods:

• Combined business economic methodology with Material Flow Analysis (MFA).
• Investigated two case studies: Initial Sorting in a Material Recovery Facility (MRF) and an improved mechanical recycling process for flexible plastics (Quality Recycling Process).
• Assessed the entire recycling chain to understand interdependencies and cost influences.

Main Results:

• The cost of Initial Sorting for flexibles is estimated at 110.08-122.53 EUR/t.
• The cost for Additional Sorting and Improved Recycling ranges from 566.26 EUR/t (rPE Flex) to 735.47 EUR/t (rPP Film).
• Rationalization of the Quality Recycling Process can reduce costs by 15-26% per tonne.

Conclusions:

• Holistic assessment of the recycling chain provides more accurate costings for recycled plastic products.
• Identified pitfalls and operational parameters significantly influence subsequent costs.
• The findings support the determination of fair pricing for recycled plastic products and highlight potential for cost reduction through process optimization.